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Nanoparticles reinforced polymer composite films have been widely studied for their enhanced mechanical, electrical and thermal properties compared with host polymer matrix. However, most research was conducted on incorporation of nanoparticles in polymer films to improve single property and there is a lack of research on the multifunctional polymer nanocomposite films. In this work, a scalable and continuous spray deposition process was developed for the production of nanoparticles reinforced multifunctional thermoplastic nanocomposite films. This process is capable of making a thin sheet of thermoplastic nanocomposites with high nanoparticle loadings. The smallest thickness can be 40um. The objective of this study is to design and optimize the thermoplastic nanocomposite films by utilizing nanoclay and helical carbon nanotube for multifunctional application: a) high electrical conductivity and thermal stability. Helical carbon nanotube paper based thermoplastic polyurethane nanocomposite films have been studied. The electrical conductivity and thermal stability of nanocomposite films increase a lot due to the incorporation of helical carbon nanotube paper with high electrical and thermal conductivity. The peculiar helical configuration of carbon nanotubes could greatly improve the interfacial bonding between carbon nanotubes and polymer matrix. b)High wear resistance and thermal stability. A nanoclay reinforced thermoplastic polyurethane nanocomposite coating was applied on the surface of leather. Due to the high hardness and thermal stability of nanoclay, the leather coated with nanocomposite film showed an improvement of wear resistance and thermal stability.